Electrical connector



Och 2, 1945. V, E` CARLSON 2,385,792

ELECTRICAL CGNNECTOR Filed Aug. 17, 1942 2 Sheets-Sheet 1 i INVENTOROct. 2, 1945. v. E. cARLsoN 2,385,792

ELECTRICAL CONNECTOR Filed Aug. 17, 1942 2 Sheets-Sheet 2 INVENTORPatented Oct. 2, 1945 ELECTRICAL CONNECTOR Vernon E. Carlson, ShortHills, N. J., assigner to Aircraft-Marine Products, Inc., Elizabeth, N.J., a corporation of New Jersey Application August 1'! 1942, Serial No.455.034

3 Claims.

This invention relates to terminals for electrical conductors and, morespecically, to terminals of the solderless type wherein a ferrule isattached by crimping, for example, to the end of an insulated conductor.

It is an object of this invention to provide an electrical connectoradapted to connect a terminal or other electrical device to anelectrical conductor by a simple crimping or upsetting operation.

A further object is the provision of a novel and improved electricalconnector wherein the end `of an electrical conductor is sealed fluidtight Within the connector, thus avoiding both possible corrosion whichmight reduce the efciency ot electrical contact and any possibility ofleakage from the end of the conductor and through its interstices if theconductor should pass through a bulkhead or the wall of a pressurechamber.

A further object of the invention is to provide a multi-part connectorin which one part for application to the conductor may be standard for-a substantial range of connectors and may be readily connected andsecured to another part.

Further objects and advantages will be in part pointed out as thedescription proceeds and will in part become apparent therefrom.

In the drawings, I have shown and described a preferred embodiment of myinvention and various modifications thereof; but it is to be understoodthat these are not intended to be exhaustive nor limiting of theinvention, but on the contrary are given for purposes oi' illustrationin order that others skilled in the art may fully understand theinvention and the principles thereof and the manner of applying it inpractical use so that they may modifly and adapt it in various forms,each as may be best suited to the conditions of the particular use.

In the drawings, in which exemplary embodiments for attaining the aboveobjectives are set forth and in which like reference characters refer tolike parts throughout:

Figure 1 is a plan view. with parts broken away and parts in section, ofa novel and improved solderless connection embodying the invention;

Figure 2 is a plan view. with parts broken away and parts in section, ofa modied form of solderlessv connection embodying the invention;

Figure 3 is a view, partly in longitudinal section and partly in sideelevation, o! a still iurther form of solderless connection embodyingthe invention;

Figure 4 ls a view, partly in longitudinal section and partly in sideelevation, of yet another i'orm of solderless connection embodying theinvention;

Figure 5 is a view, partly in longitudinal section and partly in sideelevation, showing the thimble of Figure 4 before it is applied to anelectrical conductor;

Figures 6 and 7 are, respectively, a longitudinal pian view and ,anelevational end view of another type of connector embodying theinvention; and,

Figures 8 and 9 are, respectively, a longitudinal plan view and anelectrical end view o! still another type of connector embodying theinvention.

Referring to Figure 1, a solderless connection is illustrated between anelectrical conductor, indicated generally by C, and a terminalconnector, indicated generally by T. Conductor C comprises insulation I4and a wire II made of a number of tinned copper strands. The electricalconductor is of a usual insulated stranded wire type commonly found inaeroplane controls. automobiles, radios, and the like. 'I'he connector Tconsists of a terminal contact portion I8 and a rolled or drawn ferruleportion I9. 'I'he invention is suited to use with other types ofterrules, however, and might advantageously be combined with a greatvariety of different types of connections. The conductor C and ferruleportion I9 illustrated and described are shown merely by way of example.

Between conductor C and connector T there is shown a thin metal thimble,indicated generally by 20. The closed end 22 of thimble III has beenupset against an edge of the ierrule portion I9. Central portion 23 ofthimble 20 tits over the stripped end of wire IB, and open end 24 ofthimble 20 has been expanded and fitted over the end of insulation Iloi' the conductor. Ferrule portion I9, together with the central portion23 of the thimble, is crimped onto the wire IB to form a tightelectrical and mechanical connection between the conductor, the thimble,and the ferrule. The open end portion 24 of thimble 20 may also becrimped or otherwise compressed onto the insulation to form a iirmsupport and a fluid tight seal therefor. Additional sealing means, e.g., an adhesive cement or plastic, may be used if desired between thethimble 20 and the conductor C, but ordinarily this will not benecessary ii' the end 2l is suitably compressed onto the insulation Il.

Referring to Figure 2, conductor C and connector T are of the same typeas illustrated in Figure 1. A thin metal thimble a is illustrated inposition over the stripped end of wire il and inside of ferrule i9.Thimble 20a has been upset near its outer end, as at lla, and hanged atits open end, as at 24a, to engage ferrule Il. The ferrule il may becrimped onto the wire Il and the thimble 20a to form a tight electricaland mechanical connection.

In this embodiment of the invention, a band of insulating material (notshown) may be used as a sheath to insulate the ferrule i! and to suDpOrtit from the insulated portion of the conductor C beyond 24a, and thismay also assist, by compression or cementing, in sealing the thimble 20ato the conductor C.

Referring to Figure 3, conductor C is similar to that illustrated inFigures 1 and 2. The connector, generally indicated by T', consists of aterminal portion IIb and a ferrule portion Ilb. Portions ilb and IBb areheld together, as shown, by the upset head 22h of a thin metal thimble20h. In some instances it may be desirable to hold portions IBb and I9btogether, as by brazing them or soldering them, either before or afterthey are applied to the electrical conductor. The open end 2lb ofthimble 20h has been enlarged and fitted over the end of insulation ilof the conductor and the peripheral edge of the end 2lb has been foldedback into the thimble and crimped, or otherwise compressed, intoinsulation Il, as indicated at 26. This edge may be formed and appliedin accordance with the copending application of Vernon E. Carlson andThomas C. Freedom, Serial No. 459,624, filed September 25, 1942. As inthe examples of Figures 1 and 2, the ferrule Nb, together with thecentral portion 23h of the thimble 29h, may also be crimped onto wireIl.

The ferrule lib may be omitted if the central portion 23h of the thimbleis made sufilciently heavy to serve alone and is stepped near its end toprovide a seat against which the terminal contact member Ib may beriveted. Such an embodiment is illustrated in Figure 4, wherein terminalconnector T' is shown attached to conductor C by thimble 29o. Figure 5representa thimble 2I|c before it is applied and upset onto theelectrical conductor. Preferably it is made from sufilciently heavystock to provide full strength in the electrical connection.

Figures 6 and 'l illustrate an electrical connector wherein thimble 20dis rolled and formed with tabs and ears integral with terminal connectorT. The ears and tabs are rolled and formed, as illustrated, and theseams may be sealed by soldering or by brazing, for example.

Figures 8 and 9 illustrate an electrical connectar wherein thimble 29eis formed with an enlarged open end 24e. In this embodiment the centralportion 23e and enlarged end 24e are drawn directly into theconfigurations illustrated and the seam where the edges meet is sealedas by soldering or by brazing. A connector may be attached to anelectrical conductor in much the same manner as the members of Figures 1or 3.

The erimps illustrated in the various forms between the thimble and thewire and between the thimble and the insulation are illustrative onlyand are not intended to delineate the precise extent to which anyparticular crimp may be lmassunse i The forms of the ferrule and of theterminal connector also are illustrative. Obviously other forms ofterminals may be used: and the principle of the closed thimble made bystamping and rolling from flat stock may be used with other fornais, e.g., without the portion 24d, as in Figure From the foregoing, it will beseen that connections made in accordance with the present invention arewell adapted to attain the ends and objects hereinbefore set forth andto be economically manufactured. The connections are watertight andhence eliminate corrosion and/or electrolysis between the wire and theterminal, whether they are of bright copper, aluminum, or tinned orsilvered copper or aluminum, or other conducting material. In addition,the intermediate thimbles serve to center and conne the wire of theconductor so as to assure solid en gagement with the exterior portionduring a subsequent crimping operation. Because of the thimble, the wirecannot escape to one side of a crimp or work its way between the edgesof a rolled ferrule. Furthermore, the invention reduces the number ofsizes oi' ferrules which must be kept in stock, since a relatively smallwire may be coupled with a relatively large ferrule by using a thimbleof proper dimensions and, as shown particularly in Figure 3, a fewstandard sizes of ferrules and/or thimbles may be used with a widevariety of terminal connectors each made as a simple stamping, etc., ina single standard size.

Not only does the thimble of the invention afford the above advantagesamong others, but also it may, by reason of its shape and the upset ofits end, serve as a rivet or holding member between the various portionsof a ferrule and a conductor; and if previously secured in tightelectrical contact with the conductor may thus make unnecessary anycrimping of the ferrule.

In the use of these connectors the thimble 2li may be assembled with theconnector T at the factory, the end portion as at 22 being pressedagainst one end of ferrule portion I9, so as to give a mechanicallysecure and electrically emcient and moisture tight connection and theopposite end as at 24 being formed into an abutment against the otherend of ferrule portion i8. The connector thus assembled may be slippedonto the end of the bared conductor, as shown in the drawings. and thensecured and sealed thereon, e. g., by crimping the end 2l .and theferrule I9 with a tool such as disclosed in cepending applications ofVernon E. Carlson, Serial No. 455,033, filed August 1'7, 1942, nowPatent No. 2,359,083, dated September 26, 1944, and of U. A. Whitaker,Serial No. 455,039, filed August 17, 1942. Or, instead of assembling thethimble and connector at the factory, this may be done on the job; and,likewise, the thimble may be assembled with and secured to the wire I8at the factory or on the job. Thus, the thimble may be slipped over thebared end of the conductor and crimped or otherwise secured to the wire;and subsequently the wire and thimble together may be pushed into theterminal connector T-either into the ferrule Il of Figures i and 2, orinto the hole in the simple terminal contact member IIb of Figure 3. Thewire and thimble assembly may assunta then be secured to the terminalconnector by upsetting the end of the thimble as shown.

I claim:

l. An electrical connector comprising a terminal contact portion and athimble-receiving ierrule portion, and a thin metal thimble having aclosed end, and an open end adapted to receive the end of an electricalconductor; said thimble being embraced within said ferrule portion, andthe closed end of said thimble being upset over an edge of the ferruleportion toward the terminal contact portion and another portion of thethimble being extended over an opposite edge of the ierrule portion,whereby the thimble is secured in position in the ferrule portion.

2. An electrical connector comprising a terminal contact portion and a,rolled ferrule portion, and a metal sleeve for receiving an end of anelectrical conductor; said sleeve being relatively thin with respect tosaid ferrule portion and CERTIFICATE GF CORREC 'I'ION Patent No.2,585,792.

VERNON E.

being telescoped and embraced within said ferrule portion, one end ofsaid sleeve being enlarged for embracing insulation on the electricalconductor and forming an abutment for one edge of said ferrule portion,and the other end of said sleeve being deformed laterally to engage anopposite edge portion of said ierrule portion, whereby said ferruleportion is held against said abutment.

3. In combination with a terminal connector having a ferrule to receivean end of an electrical conductor, an imperforate thimble making a tightt within the ferrule; said thimble being rela;- tively thin with respectto said ferrule and having a closed end thereof upset against one end ofthe errule and an open end thereof ared over the opposite end of theferrule.

VERNON E. CARLSON.

oc toner 2, 19h15.

CARISON.

It is hereby certified that error appears in the printed specificationof the above numbered patent requiring correction as follows: Page l,second column, line 16, for "electrical" read elevational-mg and thatthe said Lettere Patent should be read with this correction therein thatthe same may conform to the record of the case in the Patent Office.

signed and sealed this 19th day or maren, i. D. 19h45.

(Seal) Leslie Frazer First Assis tant Conmissioner of Patents.

assunta then be secured to the terminal connector by upsetting the endof the thimble as shown.

I claim:

l. An electrical connector comprising a terminal contact portion and athimble-receiving ierrule portion, and a thin metal thimble having aclosed end, and an open end adapted to receive the end of an electricalconductor; said thimble being embraced within said ferrule portion, andthe closed end of said thimble being upset over an edge of the ferruleportion toward the terminal contact portion and another portion of thethimble being extended over an opposite edge of the ierrule portion,whereby the thimble is secured in position in the ferrule portion.

2. An electrical connector comprising a terminal contact portion and a,rolled ferrule portion, and a metal sleeve for receiving an end of anelectrical conductor; said sleeve being relatively thin with respect tosaid ferrule portion and CERTIFICATE GF CORREC 'I'ION Patent No.2,585,792.

VERNON E.

being telescoped and embraced within said ferrule portion, one end ofsaid sleeve being enlarged for embracing insulation on the electricalconductor and forming an abutment for one edge of said ferrule portion,and the other end of said sleeve being deformed laterally to engage anopposite edge portion of said ierrule portion, whereby said ferruleportion is held against said abutment.

3. In combination with a terminal connector having a ferrule to receivean end of an electrical conductor, an imperforate thimble making a tightt within the ferrule; said thimble being rela;- tively thin with respectto said ferrule and having a closed end thereof upset against one end ofthe errule and an open end thereof ared over the opposite end of theferrule.

VERNON E. CARLSON.

oc toner 2, 19h15.

CARISON.

It is hereby certified that error appears in the printed specificationof the above numbered patent requiring correction as follows: Page l,second column, line 16, for "electrical" read elevational-mg and thatthe said Lettere Patent should be read with this correction therein thatthe same may conform to the record of the case in the Patent Office.

signed and sealed this 19th day or maren, i. D. 19h45.

(Seal) Leslie Frazer First Assis tant Conmissioner of Patents.

